Ultrasonic forming of confectionery products

ABSTRACT

The invention provides for the manufacture of food products. In one preferred form, methods and apparatus are provided for cutting individual confectionery products from a slab or strip of product material into a product with a particular silhouette. In another form, the invention provides methods and apparatus for both cutting and forming individual confectionery products from strips or ropes. The process can be used for simply forming products from pre-cut segments or other blanks of confectionery material, including imparting a relatively precise texture, finish or detail to such products. The products may, but need not, be subsequently enrobed in chocolate or another coating. In still other embodiments, the confectionery material may comprise grains of a puffed cereal. In some instances, a matrix of plasticizable material holds the grains together and the confectionery material may also include, in addition to the puffed cereal, candied fruit bits, dry fruits, nuts, or the like. In some cases, the puffed cereal may be held together by surface contact between adjacent grains instead of being held by the matrix.

BACKGROUND OF THE PRESENT INVENTION

[0001] This application is a continuation-in-part of application Ser.No. 08/701,394, filed Aug. 22, 1996. The present invention relatesgenerally to the manufacture of food products. In one preferred form,the invention relates to methods and apparatus for cutting individualconfectionery products from a slab or strip of product material into aproduct with a particular silhouette. In another form, the inventionrelates to methods and apparatus for both cutting and forming individualconfectionery products from strips or ropes. Still further, the processcan be used for simply forming products from pre-cut segments or otherblanks of confectionery material, including imparting a relativelyprecise texture, finish or detail to such products. The products may,but need not, be subsequently enrobed in chocolate or another coating.In still other embodiments, the confectionery material may comprisegrains of a puffed cereal. In some instances, a matrix of plasticizablematerial holds the grains together and the confectionery material mayalso include, in addition to the puffed cereal, candied fruit bits, dryfruits, nuts, or the like. In some cases, the puffed cereal may be heldtogether by surface contact between adjacent grains instead of beingheld by the matrix.

[0002] The methods and apparatus are adapted to create individualconfections which have the same taste, consistency and eatingcharacteristics as those of the supply stock, i.e., they are “trueanalogs” of the supply stock. These methods and apparatus advantageouslyinvolve the utilization of ultrasonic energy.

[0003] The simplest form of apparatus involves cutting shapes from aslab or suitably wide strip of material on a flat surface to createproducts having a given silhouette but opposed flat sides. More complexforms of the apparatus use one or more forming tools, each of whichincludes a cavity having interior surfaces which will impart a desiredshape and surface detail or texture to the finished product. Whereadvantage is taken of a number of features of the invention, acontinuous extruded strip or “rope” of confectionery material iscontinuously advanced and then intermittently engaged by a cutting andforming tool whose cutting edges and interior surfaces vibrateultrasonically at a desired amplitude. As used herein, “tool” simplymeans the portion of an ultrasonically energized apparatus that cuts orimprints a shape to the product.

[0004] This enables a finished product of a desired shape and surfacetexture to be accurately formed by the tool and then released from thetool without having any residue from the product adhere to the interiorof the tool, and without affecting the sensory characteristics of theproduct. The apparatus and methods can be used to create products whichare the true analogs of other products made from the same ingredientsbut shaped or sized differently.

[0005] Where the cutting and forming tools are formed and sizedappropriately, and moved in a desired sequence, and where thecross-section of the confectionery stock is controlled properly, theprocess can achieve so-called “flashless molding” of product and alsovirtually or completely eliminate scrap or the like by forming theentire strip into individual products, without leaving a web or otherresidue from which the individual pieces were formed. In the case ofpuffed cereal products, this may be referred to as “flashless formation”in that little or no scrap is created by the forming operations. Formingof puffed cereals is done by rearranging the shape or contours of theproduct, but without compressing the confectionery stock. This avoidsany change in eating characteristics which might result from compressingor collapsing the cereal grains.

[0006] Many commercially produced confectionery products, such as, forexample, candy bars, are formed by providing a slab which is then slitinto multiple strips or what are sometimes termed “ropes.” These stripsor ropes are cut into individual lengths and enrobed with a continuouscoating, such as, for example, chocolate. Such cutting steps can becarried out at high speed but these steps do not customarily involveforming the product into any shape except that of simple geometricfigures, usually a parallel piped or rectangular bar.

[0007] Although it is known to be possible to form unusual shapes and toimpart a great variety of surface finishes or textures to candyproducts, this is not able to be done with most candy products on arapid, continuous basis. This is because such shapes are normallycreated by molding, which involves melting the candy product andallowing it to re-solidify.

[0008] In the candy business, a great deal of research and effort hasbeen undertaken in an attempt to create products which have taste,consistency and eating characteristics of a particularly desired kind.Thus, candy bar centers are commonly made as layered products andinclude a variety of materials each having its own characteristic taste.These ingredients include nuts of various kinds, fruit inclusions,coconut, peanut butter, nougat, caramel, most or all of which arelayered and then enrobed in dark or light chocolate, or the like. It hasbeen found through research that the mere presence of the same orsimilar ingredients in two different products is not enough to ensurethat they will have the same taste, consistency and eatingcharacteristics.

[0009] Thus, if the ingredients in one product are arranged in distinctlayers, and in other products the same ingredients are simplyintermixed, consumers will very often strongly prefer one product andnot the other, in spite of the virtual identity of their ingredients onan overall basis. Many manufacturers have been unable to offer trulyanalogous products in shapes which differ significantly from those inwhich the products are customarily made. Accordingly, there has been adesire in the industry to be able to provide different versions or trueanalogs of particular, commercially popular candy bars in shapesdifferent from their usual prior shapes. By “true analogs” as usedherein is meant a product which does in fact have the same formulation,taste, consistency and eating characteristics as an original orreference product.

[0010] Assuming that a product itself could be made into two or moreanalog forms, each having significantly different shapes, anotherquestion is whether the equipment used to make such analog productscould be readily incorporated into existing production lines.

[0011] Consequently, the operational flexibility that could be achievedby simply inserting the apparatus necessary to make an analog productinto a production line that need not otherwise be modified would be asignificant advantage in the industry.

[0012] While it is known that three dimensional products or those withcomplex detail or surface texture can be formed from continuous slabs ofmaterial as described above without encountering the above-referenceddifficulties to an extent considered significant, these knownmanufacturing methods have several of their own drawbacks. Such methodsoften termed “flex molding,” for example, are expensive and complex.

[0013] Flex molding is so-named because the molds which actually formthe product are made from a flexible material, such as rubber.Consequently, it is possible to impart a somewhat complex decorative orlike shape to the product and to remove a product, even one includingundercuts or complex surface shapes from the mold as long as the moldsidewalls are flexible enough to be removed from the product withoutdamaging it. However, there are a number of drawbacks to this method.First, it involves fluent, plasticized or even liquid state products,and such liquid state products cannot by their nature be true analogproducts. The time required to allow products to solidify sufficientlyto allow their removal is a process requirement that militates stronglyagainst high production rates.

[0014] The size and complexity of flex molding equipment makes itexpensive, causes it to occupy a great deal of space and makes itdifficult to integrate into existing process equipment. Maintenance insome cases is difficult and expensive.

[0015] At least one other prior art method has presented certaindisadvantages and drawbacks. Among these are problems of adhesionbetween the tool cavity interior or other forming surface that canbecome very significant. Even the most minor amount of adhesion willprevent complete product release, and in this case, deposits canprogressively build up until an unacceptable level of residual materialis present. Then, the process must be stopped to clean the formingsurfaces. Anything hampering the continuity of such a process is clearlya serious drawback.

[0016] Problems continue to arise in the confectionery industry when itis necessary to cut individual pieces from continuous slabs, strips orextrudable ropes of products. Another aspect of the difficulty incutting pieces relates to commercially produced frozen confections suchas ice cream or frozen yogurt. The present invention allows effortlesscutting of slabs, strips or extrudable ropes without producingdistortion or adhesions, even where there are inclusions such as nuts,bits of fruit and the like.

[0017] The puffed cereal material may be presented in several ways.Where the cereal grains are received and held within a plasticizablematrix, the strip or slab of such product may be reformed at any timeafter the strip or slab itself is formed, inasmuch as the grains can bemoved about when the matrix is plasticized. The operations includecutting individual pieces from a larger mass such as the strip or slaband forming them into characteristic shapes or products with visiblesurface texture. In those circumstances wherein there is noplasticizable matrix, it is customary to form an extruded rope of grainsbound together at their outer surfaces without an adhesive matrix. Thisextruded rope is still pliable for a very short time immediately aftermerging from the extruder. It is only at this point that the rope may beformed into a confection of a shape determined by the tool contourswithout altering the texture or volume of the grains and withoutaltering the eating characteristics of the final product.

[0018] In view of the foregoing and other disadvantages and the failuregenerally of the prior art to provide optimum methods and apparatus forforming individual food products from continuous strips or slabs, it isan object of the present invention to provide improved methods andapparatus for this purpose.

[0019] Another object of the present invention is to provide an improvedapparatus and method for simultaneously cutting and formingconfectionery products such as, for example, candy bars.

[0020] One other object of the present invention is to provide anapparatus which will rapidly and readily cut a product having a givensilhouette from a continuous web of material.

[0021] A further object of the present invention is to provide improvedmethods and apparatus for cutting and forming frozen confectioneryproducts, with or without inclusions.

[0022] A still further object of the present invention is to providemethods and apparatus for ultrasonically cutting and forming threedimensionally shaped and/or surface textured or embossed confectioneryproducts, both “frozen” or “ambient” (“non-frozen”).

[0023] Another object of the present invention is to provide an improvedmethod and apparatus for ultrasonically energizing one or more “acoustictools” (such as an ultrasonic horn) used to cut and form intricatelyshaped, surface textured confectionery products from a continuous slab,rope or strip.

[0024] A further object of the invention is to use an acoustic tool forforming confectionery products, including puffed cereal products, frompre-cut, metered, or dosed portions of confectionery stock.

[0025] Yet another object of the invention is to provide an improvedmethod and apparatus for minimizing distortion of layered feedstockmaterials during the forming process.

[0026] A further object of the invention is to provide a method andapparatus for cutting and forming intricately shaped and/or texturedconfectionery products in a single step, such methods and apparatusemploying ultrasonic energy and specially designed forming tools.

[0027] A still further object of the present invention is to provide animproved method and apparatus for cutting individual confectioneryproducts from a strip or extruded rope of confectionery stock andsimultaneously forming individual products by contacting the supply ofmaterial with a cutting and forming tool having ultrasonically vibratingsurfaces.

[0028] Yet another object of the present invention is to provide amethod and apparatus for forming confectionery products which readilyfill a cavity of a complex shape to provide a product that issubstantially free of voids.

[0029] A further object of the present invention is to provide a methodand apparatus whereby confectionery products of a given height, lengthand width can be produced from a continuous strip of confectionery stockhaving a different height and width, all without disturbing the taste,consistency and eating characteristics of the feedstock.

[0030] An additional object of the invention is to provide an improvedcutting and product forming system for making selectively shapedconfectionery products, which system can easily be integrated into orinstalled on existing production lines with a minimum of capitalexpenditure and which can enable such production lines to achievedesirably high production rates, especially in relation to flex moldingtechniques and to maintain or improve quality.

[0031] Another object of the present invention is to provide a methodand apparatus for substantially reducing the forces required to formnovel confectionery shapes, thereby increasing the life of tools andother process equipment, and enabling products to be made at higherrates without increased cost.

[0032] A still further object is to provide a process that is capable ofconcurrently producing both regular or conventional shapes as well asnovelty shapes from the same feedstock, preferably on side-by-side linesusing basically the same equipment.

[0033] Yet another object of the present invention is to provide aconfectionery forming method and apparatus wherein ultrasonic energy isused to achieve movement of the cavity defining surfaces to ensure thatthe product is fully and completely released from the mold therebyeliminating build-up of product residue on the working faces of theforming tools.

[0034] A further object of the invention is to provide a method ofoperating an ultrasonically energized tool so as to achieve the requiredenergy transfer without waste of energy or degrading or damaging to theproduct or the tooling.

[0035] Another object of the invention is to provide methods foroperating ultrasonically energized equipment which include selectivelyvarying the amplitude of vibration undergone by certain of the productcontact surfaces during the cutting and forming cycles so as to utilizeultrasonic energy in the most effective way.

[0036] A still further object of the invention is to provide a method ofimparting ultrasonic energy to an ultrasonically vibrated mold in adefinite sequence so as to achieving desired or necessary plasticity andsecure complete mold release without unduly raising the surface and/orinterior temperature of the product.

[0037] An additional object of the present invention is to providemethods for utilizing pairs of opposed, cooperating, ultrasonicallyenergized forming tools in a synchronized relation to form products ofcomplex shapes, including full three-dimensional shapes, in a continuousprocess.

[0038] Another object of the invention is to enable the same processequipment to be used in forming finished products such as fudge orchocolate products, as is used in producing toffee or other shapedcenters for a subsequently applied final coating such as chocolate.

[0039] A further object of the invention is to provide a molding toolwhich will cut profile or silhouette shapes from a slab of continuousconfectionery feedstock, creating a product with a flat top and bottomand a contoured outline or silhouette formed by a precise, ultrasonicvibration-assisted cutting action.

[0040] Yet another object of the invention is to provide a method ofsubstantially “flashless” molding of confectionery products from acontinuous strip, rapidly forming a succession of individual productsand utilizing the entire volume of the strip so that no residual web ornon-product residue is created.

[0041] Another object of the invention is to utilize a multiple cavitytool to produce plural flashless, silhouette products from a slab toleave a web of minimum volume that can be recycled.

[0042] Yet another object of the invention is to use an array of singleor multiple cavity tools for producing silhouette products or cut andmolded products from a slab of confectionery material.

[0043] A further object of the invention is to provide certain apparatusand methods that will cut and/or form confectionery stock such as candybar forming stock, and in modified or unmodified form, that willfunction equally well in cutting and/or forming puffed cereal slabs,strips or ropes of various kinds.

[0044] A still further object of the present invention is to provide amethod of incorporating the intermittent motion of a pair of opposedtool sets into a process that includes supplying feedstock in continuousor rope form in order to make individual products from such continuousrope without creating waste, leftovers, and without unduly deforming thefeedstock.

[0045] The foregoing and other objects and advantages are achieved inpractice by providing a method which includes using one or moreultrasonically energized forming tools to create individualconfectionery products, including puffed cereal products, from acontinuous slab of product by cutting and forming such individual usesthrough the use of a desired motion sequence, and the use of theultrasonic energy to plasticize the product and impart a desired shapeand surface texture thereto at high speed while securing completerelease of the product from the forming tool.

[0046] The objects are also achieved by providing control of theamplitude of the ultrasonic energy supplied to the tools during productforming operations and by coordinating the motion sequence of some ofthe process equipment with other process equipment to achievesubstantially flashless molding. In addition, the invention providemethods and apparatus involving the use of a reciprocating tool movingin cooperation with an indexable companion tool or anvil as a part of acontinuous forming process.

[0047] The manner in which the foregoing and other objects andadvantages are achieved in practice will become more clearly apparentwhen reference is made to the following detailed description of thepreferred embodiments of the invention set forth by way of example andshown in the accompanying drawings, wherein like references numbersindicate corresponding parts throughout.

BRIEF DESCRIPTION OF THE DRAWINGS

[0048]FIG. 1 is a perspective view, with portions broken away, showingcertain important elements of a preferred form of apparatus for formingindividual confectionery products from a continuous supply ofconfectionery feedstock;

[0049]FIG. 1A is a side elevational view of the apparatus of FIG. 1;

[0050]FIG. 2 is a top plan view of the apparatus of FIG. 1, showingcertain of the structural and operational aspects thereof;

[0051]FIGS. 3A, 3B & 3C illustrate detailed forms of confectioneryproducts respectively formed by associated cutting and forming toolshaving shaped and textured interior forming surfaces;

[0052]FIG. 4 is a perspective view, partly diagrammatic in nature,showing the use of a pair of opposed, ultrasonically energized toolsused to form individual products from a continuous strip ofconfectionery material that is advanced and formed intermittently;

[0053]FIG. 5 is a fragmentary elevational view of a portion of theapparatus of FIG. 4;

[0054]FIG. 6 is a front elevational view of a pair of the ultrasonicallyenergized, reciprocable tool sets of the invention forming a part of theapparatus of FIG. 4;

[0055]FIG. 6A is a fragmentary elevational view similar to that of FIG.6, but showing one reciprocable tool set and one fixed tool set;

[0056]FIG. 7 is perspective view, partly diagrammatic in character,showing a further modified form of apparatus, using a reciprocating,ultrasonically energized tool periodically moved into registry with oneof a series of intermittently advanced anvils;

[0057]FIG. 8 is an enlarged front elevational view of the ultrasonicallyenergized tool and one of the anvils used with the apparatus of FIG. 7;

[0058]FIG. 9 is a schematic view illustrating how ultrasonic energyapplied to a forming tool creates low-amplitude, high frequency movementof the tool forming surfaces, and also schematically showing a standingwave with node and anti-node portions;

[0059]FIG. 10A is a perspective view of one form of an apparatus madeaccording to the invention and utilized to create multiple rows ofsingle silhouette products from multiple continuous slabs ofconfectionery stock, leaving multiple continuous webs of reusableconfectionery stock;

[0060]FIG. 10B is a view similar to that of FIG. 10A, but showingmultiple rows of ultrasonically energized cutting tools used to formmultiple groups of cut products from continuous slabs of confectionerystock, leaving plural, recyclable residual webs of confectionery stock;

[0061]FIG. 10C is a diagrammatic vertical sectional view of a portion ofthe apparatus of FIG. 10A and showing an ultrasonically energizedcutting tool in a position of use relative to a slab of confectionerystock;

[0062] FIGS. 11A-11D are amplitude-time curves showing a variation inthe amplitude of ultrasonic motion undergone by the cutting or cuttingand forming tools of the invention during certain portions of theproduct forming and release cycles of the invention;

[0063]FIGS. 12A and 12B are diagrammatic illustrations of therelationship between the length, height, width and volume of a portionof a confectionery feed strip and the volume of a finished product madefrom such feed strip;

[0064]FIG. 13 is a perspective view of a forming tool with a cavityadapted to produce the form of confectionery products shown adjacent theforming tool;

[0065]FIG. 14 is an illustrative example of a form of confectioneryproduct having a finely detailed relief face on its upper surface andmade according to the invention;

[0066]FIG. 15 is another illustration of a typical form of confectioneryproduct able to be made using the apparatus and method of the invention;

[0067]FIG. 16 is a block diagram illustrating the various steps of onepreferred form of process embodying the invention;

[0068]FIG. 17 is a perspective view, with portions broken away, showinga puffed cereal product and a portion of the forming tool used to makethe product, which is shown as being of decreased height and increasedwidth relative to the stock from which the product was formed;

[0069]FIG. 18 is a fragmentary perspective view of one portion of astrip of puffed cereal material wherein the grains are embedded in aplasticizable matrix and thus adhered to one another;

[0070]FIG. 19 is a illustration similar to FIG. 18, but showing aportion of a strip of puffed cereal containing various inclusions withinthe plasticizable confectionery matrix;

[0071]FIG. 19A is a view similar to FIG. 19, and also showing nuts orother particular kinds of inclusions;

[0072]FIG. 20 is a fragmentary sectional view of a portion of a “rope”of confectionery product wherein puffed cereal grains have just beenextruded and are held together by surface contact; and

[0073]FIG. 21 is a side view, partly in elevation and partly in section,and also somewhat diagrammatic in character, showing an ultrasonicforming tool for cutting an end portion from an advancing continuousstrip of a puffed cereal material and forming it into individualproducts of decreased height and increased width, and also showingportions of the product infeed and outfeed conveyors of the invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION

[0074] The apparatus of the present invention is capable of beingembodied in a number of forms, and the inventive process includesseveral methods all falling within the general ambit of the inventiveconcept.

[0075] Accordingly, by way of example only and not by way of limitation,a description will be given of several different forms of apparatus,each capable of practicing the invention and each having individualcomponents capable of being varied in constructional details andarrangement. Illustrative methods, the steps of which may also bemodified or altered somewhat in use, are also described herein.

[0076] Referring now to the drawings in greater detail, FIGS. 1, 1A and2 show the invention to be embodied in a confectionery product cuttingand forming apparatus generally designated 20 and shown to include alower support frame portion generally designated 22, an upper framesection generally designated 24 and a pair of conveyor units, a foodproduct input conveyor 26 and a food product output conveyor 28.

[0077] According to the invention, the lower frame 22 includes pluralspaced apart vertically extending legs 30 supporting substantiallyidentical front and rear transverse cross members 32, on which atabletop 34 is positioned. The upper frame 24 includes vertical supports36 and horizontal members 38, such members being adapted to receive andposition a pair of substantially identical horizontal actuatorassemblies generally designated 40A, 40B. The actuators 40A, 40Breciprocate a support plate 41 which in turn supports a verticalactuator generally designated 42 for a support plate 43 to which areattached a pair of spaced apart brackets 45.

[0078] According to the invention, the actuators move the support plate41 with a laterally reciprocating motion, i.e., to the left and right asshown in FIGS. 1, 1A and 2. A drive arrangement for the actuators 40A,40B includes a traversing motor 46 driving a reduction gear box assembly47 having a drive shaft 48 that rotates one carrier gear 50 in eachactuator 40A, 40B. The gears operate toothed timing belts 52 (only oneshown in FIG. 2), the lower runs of which are attached to the supportplate 41.

[0079] According to the invention, the vertical actuator includes aservo plunge motor 54, a gear box 56 cooperating in use with a verticalactuator drive shaft 58 that also moves a reciprocable timing belt 62 towhich the support plate 43 and mounting brackets 45 for the ultrasonicstack 44 are attached.

[0080] Referring particularly to FIGS. 1, 1A and 2, it will be notedthat a power supply (not shown) furnishes electrical energy through aradio frequency cable 64 to a converter 66 wherein high frequency (20KHz or higher) electric energy is transduced into vibratory mechanicalmotion, preferably by a plurality of piezoelectric transducer devices.The output of the converter 66 is amplified, if needed, in what istermed a booster assembly 68, which also provides a second clampingpoint at its nodal ring for mechanical stability. The output end face ofthe booster 68 is secured by suitable means to the upper or input end ofan ultrasonic horn generally designated 70. The horn 70 includescontoured surfaces 72 forming a product shaping cavity 74.

[0081] Referring again to FIG. 1 and in particular to the input conveyor26, this unit is shown to include a drive motor 78, a reduction geartransmission 80, a primary drive roller 82 that is operative to advancea continuous serpentine belt generally designated 84 which is trainedaround a plurality of guide pulleys 86, 88, 90, 92. When the belt 84 isdisposed as shown, there is a lower run 94 and an upper run 96 which inuse is trained over a backing plate 95 and which run 96 in turn supportsa continuous supply or strip of confectionery feedstock 98. Prior tocoming in contact with the belt forming the upper run 96 of the conveyor26, the strip advances along one or more intermediate supports 100, 102which may optionally include or be formed from a plurality ofoverlapping rollers (not shown in detail) or the like.

[0082] A mixer/extruder, or other source (not shown) may be used to forma continuous supply or slab of confectionery material having a uniformcross-section and a self-sustaining shape, arising by proper temperaturecontrol both in the case of an ice cream or other frozen confection, andin the case of a candy bar or like product. It will be understood thatthe continuous strip 98 may be only one of several strips formed from aslab of much greater width but of the same height and consistency. Inother words, the process may call for forming a slab from which severalstrips are cut and advanced as indicated herein.

[0083] Referring now to the second or outfeed conveyor 28, this unit isshown to be analogous to its counterpart on the infeed conveyor side,with the unit 28 having a motor 104, gear reduction unit 106, a driveroller 108, plural guide rollers 110 (only one numbered), and a drivebelt generally designated 111 forming upper and lower runs 112, 114respectively. This belt ill is substantially identical to itscounterpart except that, as will appear, it is intentionally driven at asomewhat higher speed. In keeping with the invention, the cavity portion74 of the tool 70 is used to form a plurality of substantiallyidentical, individual confectionery products 116 from the continuousrope or strip of confectionery material 98. The manner in which thisforming is done will now be described in detail, reference being had inparticular to the illustrations of the product in FIGS. 3A, 3B and theschematic or flow diagram FIG. 16. The manner of sizing and shaping thecavity for the product is also illustrated in FIGS. 12A and 12B.

[0084] Referring now to FIG. 3A, there is shown an ultrasonic horngenerally designated 70 having a surface 72 forming a product-shapingcavity 74 within its lower portion.

[0085] Where the cavity 74, merely by way of example, has an innersidewall 72 with some relatively smooth portions 120, a series ofdecorative embossments or the like 122 and a identifiable relief FIG.124, a finished product generally designated 116 a made using this tool70 will have the reverse image of these elements, including a reverseelement 124 a of the relief image 124, a smooth portion 120 a on theproduct sidewall 72 a and debossments or depressions 122 a formed by thecounterpart embossments or image formations 122 on the walls 72 of thecavity 74. According to the invention, a very thin knife-edge cuttingsection 126 is provided in the places where an exterior wall segment 128approaches and virtually meets a counterpart interior wall surface 72 ofthe cavity 74, typically at the trailing edge of the tool.

[0086]FIG. 3B shows another form of cavity generally designated 74 chaving a trailing, sharp cutting edge 126 c defined by the junction ofexterior surfaces 128 c and inner cavity surfaces 72 c. In theillustrated embodiment, a turtle FIG. 116d is shown to be produced bythe turtle shape of the cavity 74 c. In addition, a decorative reliefsurface 124 d is shown to be formed on the figure by counterpartformations 124 c within the cavity 74 c.

[0087]FIG. 3C shows still another form of tool 74 f having a cavity 74 gadapted to form a product 116 f wherein the cutting edges or surfaces126 d are used to form vertical sides 119 of the product similar tothose of the silhouette type.

[0088] The foregoing descriptions illustrate that individual cavitiesmay have irregular or complex shapes that may include relief and/orrecessed portions adapted to create on the formed piece respectivelydepressions and/or relief figures, and that any part or all of thecavity surface may be textured as desired to make the preferred form ofproduct.

[0089] If the pieces are to be sold as formed, the relief or finishsurface may be fine or coarse. If the pieces are to be enrobed, thenature and extent of surface detail will be selected so that a desiredimage will remain visible through the coating.

[0090] Referring now to the operating sequence and method of theapparatus of FIGS. 1 and 2, FIG. 16 is a block diagram illustrating theprocess of the invention in a general way. As shown in the first block,a strip of material is advanced at a predetermined rate. The next stepcomprises moving the tool 70 at a synchronous rate with the advancingstrip and then, while the tool continues to advance, moving itdownwardly with a rapid motion into contact with the strip 98. Here, theproduct is formed when the tool moves through the strip segment andmeets the upper run 96 of the belt 84, where the belt is supported bythe backing plate 95. In the next step, the tool remains in a downposition and is accelerated forwardly away from the remainder of thestrip 98 for a brief time before the tool is raised and returned to theinitial point. Finally, in the last step, the previously formed,released, and separated piece 116 is transferred to the faster movingoutput conveyor for further separation while at the same time, the tool70 (and in fact the entire stack) is lifted and rapidly reset to itsinitial position before beginning the synchronous forward-and-downmovement sequence described above. The apparatus then repeatedly carriesout the cycle just described.

[0091] In the machine shown in FIGS. 1, 1A and 2, therefore, as thestrip of material 98 is advanced, the transverse and vertical movementmechanisms for the ultrasonic stack 44 are both actuated. The stack isadvanced as its support plate 41 moves it forward under the control of aprogrammable servo motor or otherwise such that its translational speedis identical to the advance speed of the infeed conveyor belt 84.Consequently, beginning in an initial part of the stroke whichcorresponds generally to a flat segment 99 of the conveyor illustratedas just above the backing plate 95 lying between rollers 88 and 90, thetool 70 moves downwardly at a rapid rate, stroking to a position whereinits cutting edge 126 (FIG. 3A) is substantially in contact with theupper surface of the belt 84.

[0092] The vertical travel mode of the servo driven plunge motor 54moves the plate 43 to accomplish this movement sequence. As will bedescribed in detail later, this movement sequence simultaneously cutsand forms a shaped product 116 through a combination of compressiveforce and vibrational energy transfer, without affecting the texture orsensory characteristics of the product.

[0093] As the cutting edge 126 approaches or just contacts the belt 84,the traversing motor 46 accelerates the belt 52 controlling movement ofthe support plate 41, advancing the edge 126 slightly in respect to thelinear speed of belt 84. This desirably separates the just-formed piece116 from the leading edge 113 (FIG. 12A) of the strip or rope ofconfectionery product 98.

[0094] The individually formed product 116 and the leading edge 113 ofthe strip are now moving forward at the same speed but are slightlyspaced apart. Thereupon, with continued operation of the input conveyor26 at its rate and the continued operation of the output conveyor 28 atits own higher rate, an overdriven velocity is created in the outputbelt 111. The articles 116 just formed are thus picked up, furtherseparated and moved away to a remote section of the table 34, as shownat the right hand sides of FIGS. 1 and 2. As the ultrasonic stack 44 islifted to free the product 116 from the interior of the cavity 72, thetraversing motor 46 actuates the mechanism to rapidly reset the stack toan upstream or far left position as shown in FIG. 1. The advancing (orleft to right as shown in FIG. 1) synchronous motion is then the firststep in a new cycle, and so on.

[0095] According to the invention, and as will be described elsewhereherein, the movement profile of the tool 70 is such that its cuttingedge 126 will contact the continuously advancing rope of confectioneryproduct 98 a distance spaced inwardly of its leading edge an amountsufficient to cut an individual portion of a desired volume. Themovement sequence thus described is a simple one which is periodicallyrepeated, with each individual confection being made from apredetermined volume of the strip or other supply of confectionerystock.

[0096] According to the preferred form of the invention, a servo motoror other programmable sequence drive arrangement is provided so thatindividual portions are made, each of which is of an identical size, andthe advancing and retreating motion as well as the downward or plungestroke of the ultrasonic stack are coordinated such that a piece of thedesired volume, but different shape, is cut with each cutting sequenceand then molded into a different shape of identical volume. As willappear, this enables the process to be carried on without leaving a webor other waste in what is essentially a flashless, rapid formingoperation not requiring any compromise in the analog characteristics ofthe finished product.

[0097] Referring now to a corollary of the concept that flashlessmolding is possible, and that waste formation can be eliminated,reference is made to FIGS. 12A and 12B. Here, FIG. 12A is an elevationalview, partly in section and showing the bottom portion of the tool 70having interior surfaces 72 forming a cavity generally designated 74,shown in FIG. 12A to possess a volume V₂. FIG. 12A shows that the cavity74 is also defined by and includes a trailing, cutting edge portions 126and a leading edge 127, so named in view of the travel direction of thestick or strip 98 of confectionery product.

[0098] As shown in FIG. 12A, the cavity 74 has a length L₂. A selectedlength L₁ forms a strip segment 98 a that is shown to have a volume V₁which in the illustrations of FIGS. 12A and 12B is shown to result fromits also having a height H₁ and a width W₁. In the illustrated form, H₁is greater than the maximum height H₂ of the cavity 74 and the widthmaximum W₂ of the cavity 74 is greater than the width W₁ of the strip98.

[0099] Given that the volume V₂ of the cavity 74 is able to bepredetermined by simple volumetric measurement, as having, for example,a volume of 25 cc, then theoretically, a flashless product could be madeif an individual piece of the confectionery strip 98 a is of a suitablecross-section, such as a rectangular cross-section, and also has avolume of 25 cc. This is what is in fact done according to the presentinvention, wherein, given the volume V₂ of the cavity 74, the width,height and length of the strip segment 98 a are selected so that itsvolume is the same as that of the cavity, and so that exact filling canbe accomplished.

[0100] In this connection, it is customary to have the strip segment 98a somewhat higher, shorter, and narrower than the cavity to achieveprecise results. In other words, the strip segment and cavity are shapedand sized so that the entire volume V₁ of the strip segment 98 a willinitially fit with the cavity. Since, after one cutting and formingcycle is completed, the leading edge of the strip of confectioneryproduct 98 will have an arcuate configuration, when the process ofcutting and separating is repeated, the leading edge will continue tohave such configuration, and exact matching of the volume of the stripsegment 98 a and that of the cavity interior will result so as to permitprecise flashless molding. Repetition can be accomplished in proportionto the ability of the process machinery to hold tolerances on the heightand width of the strip. Experience has proven that this is very easilyaccomplished.

[0101] Accordingly, while the reforming of the entire volume of theproduct into a cavity of the same volume and a different shape rendersit practical to achieve virtually 100% product utilization and toeliminate or at least significantly minimize generation of scrap, theinvention can be practiced without using this capability. Thus, if theinvention is used to produce silhouette products by using an ultrasonictool in “cookie cutter” fashion from a slab of confectionery product, itis implicit, as will be discussed in connection with later examples,that desirable products can be made by a process wherein a web of unusedproduct will still remain.

[0102] Referring now to FIGS. 4-6, another form of apparatus generallydesignated 200 is shown as being suitable for the practice of theinvention. Here, there is somewhat schematically shown a process forextruding a rope 202 of a confectionery material from a given source(not shown). A feed belt 204 is trained over drive and guide wheels 206,208 that are shown to be provided for advancing the rope 202 ofjust-formed product on a continuous basis. Such a continuous extrusionand advancement are considered one desirable and effective way tomaintain the uniform cross-section of product which is desired formaintenance of quality.

[0103] The rope 202 of product travels over a groove formed in the outermargin 210 of a rotary feed wheel 212 journalled on an axle 214 that issupported by a bearing 216 at the upper end 218 of a shaft 220 moved bya linear actuator 222. The axle 214 is driven by a motor 215 such thatthe speeds of the feed belt 204 and the outer diameter of the wheel 212are the same. The actuator 222 is moved controllably to intermittentlyalter the feed rate of the rope 202.

[0104] As shown in the phantom lines in FIGS. 4 and 5, the pulley orfeed wheel 212 is movable between a solid line position P₁ shown inFIGS. 4 and 5 and a phantom line position P₂ also shown in FIGS. 4 and5.

[0105] Referring again to FIG. 4 and also to FIG. 6, it is shown thatsections of the rope 202 are formed into individual contoured products242 a, 242 b, 242 c, etc., by a cutting and forming apparatus generallydesignated 240. Each product 242 a, 242 b, etc. is substantiallyidentical to every other product and all are carried away by the upperrun 244 of a conveyor (not shown in detail).

[0106] Referring to FIG. 6, it will be noted that a pair ofsubstantially identical but mirror image, left and right hand formingassemblies 246 a, 246 b are shown. The parts being essentiallyidentical, only the parts comprising the left hand portion 246 a aredescribed in detail herein. In FIG. 6, a bracket 248 is shownschematically as being adapted to reciprocate an ultrasonic stackgenerally designated 249 comprising a converter 250, a booster 252, anda horn assembly 254 in a horizontal plane. The ultrasonic horn 254 isshown to include a carrier 256, a forming tool 258 a having a contouredcavity 260 a forming a part thereof; tool 258 b has a cavity 260 b. Asshown, the cavities 260 a, 260 b resemble their counterparts shown inFIGS. 3A and 3B, and each includes contoured or otherwise desirablyshaped inner surfaces and sharp cutting edges not shown in detail inFIG. 6.

[0107] In use, it is desired to move the two ultrasonically energizedforming tools toward each other periodically to contact a desiredportion 207 of the rope 202 of product disposed therebetween to performa combination cutting and forming operation analogous to that describedin connection with FIGS. 1, 1A and 2. In this instance, considering thattwo horns must be manipulated, it is strongly desired not to attempt tosynchronize movement of both ultrasonic stacks with respect to acontinuously advancing rope or stick of product. Hence, a compensatingdrive assembly of the type shown in FIGS. 4 and 5 is utilized to alterthe feed rate of the rope 202 by changing a constant advance rate to anintermittent, advancing motion. This is accomplished by periodicallymoving the shaft 220 at an appropriate time and with an appropriatevelocity such that the peripheral groove 210 of the pulley 212 risesvertically at a rate exactly equal to the advance rate of the belt 204.During the short period when this is occurring, forward motion of theend portion 207 of the rope 202 is arrested just as forming assemblies246 a, 246 b carrying the tools 258 a, 258 b are moved together to formthe product, and to begin their separation to permit the product to beejected from the single cavity formed jointly by the two tool segments.

[0108] As the stacks are separated, the shaft 220 moves downwardly, ineffect permitting the new leading edge of the rope portion 207 to movedown, and in effect, feed another segment of the rope 202 to the formingtools. As the portion 207 completes the advancing movement, the shaft220 is moved up again by the actuator 222, and the process is repeated.

[0109] The foregoing apparatus illustrates the application of theprinciples of the invention to the cooperative use of a multiple stacksof ultrasonically energized cutting and forming tools in the productionof confectionery products. The size and shape of the rope relative tothe configuration of the cavities and the size of the final product areable to be controlled in a manner analogous to that described above inconnection with FIGS. 12a and 12 b, or otherwise as described. Othercontinuous-to-intermittent motion devices may be used for the purposedescribed above, but the preferred apparatus is one of a type whereinthe rope is supported throughout the major portion of its extent, withonly a free end portion hanging down as shown.

[0110] If this were not the case, the cross-section of the rope 202 orother extruded shape might be deformed by undue gravitational-forceelongation. The form of continuous-to-intermittent drive mechanism shownis merely one presently preferred form, it being understood that thoseskilled in the art are well aware that other mechanisms may beconstructed and arranged for this purpose.

[0111] Where the two tools containing opposed cavities meet, a compositematerial, such as a carbon fiber material, may be bonded to the end faceof one or both of the tools for purposes of shock and vibrationabsorption. It is not desirable to permit two hard metal, ultrasonicallyenergized parts contact each other while energized, particularly, undera substantial force, inasmuch as such contact may be damaging to thecomponents. Therefore, a stiff but resilient, shock-proof material suchas the composite materials just referred to may be used.

[0112] Referring now to FIG. 6A, a slightly modified form of theapparatus shown in FIGS. 4-6 is shown. Here, a left-hand formingassembly 246 c is shown and a portion of a right-hand forming assembly246 d is also illustrated. These mirror-image parts are essentiallyidentical to their counterparts 246 a, 246 b, and to each other exceptthat in this embodiment, part 246 d is fixed in position and does notreciprocate. Accordingly, in assembly 246 c there is a counterpart (notshown) to the bracket 248 shown in FIG. 6 to reciprocate the stack.However, in respect to the stack 246 d such a bracket is fixed andserves to fixedly support the non-movable stack 246 d.

[0113] Referring again to FIG. 6A, it will be understood that theassembly 246 d might also be passive, i.e., not ultrasonicallyenergized, if this were desired for some reason, such as if the productdid not present any risk of sticking or if the right-hand assembly wereonly a flat surface rather than having a cavity intended to provide acontoured or decorative relief surface to the product.

[0114] Referring now to FIGS. 7 and 8, a further modified form ofapparatus is shown. Here, a cutting and forming apparatus generallydesignated 300 is shown to include drive means in the form of a powereddrum or sprocket 302 supporting a belt generally designated 304 andhaving upper and lower runs 306, 308, each carrying a plurality ofsubstantially identical anvils 310. The apparatus as shown includes, asillustrated in phantom lines, a conditioning chamber or the likegenerally designated 312 through which products 314 formed by theprocess may pass during operation. The product removal belt 316 picks upthe fully formed and in some cases conditioned products 314 from theupper run 306 of the belt 304 and positions them for transfer topackaging or other processing stations as desired. These steps could,but need not, include enrobing in chocolate or the like.

[0115]FIG. 7 shows that in the apparatus 300, a feed source generallydesignated 318 is shown to contain plural, spaced apart individualpre-cut blanks 320 to be formed into finished products 314 by theinventive process. Each of the pieces 320 is to be fed individually toone anvil of a series of identical anvils 310 passing beneath the feedsource 318. As best shown in FIG. 8, an ultrasonically energized stackgenerally designated 324 (similar to its counterpart in the otherexamples) is shown to be carried by a pair of brackets 326 secured to areciprocable plunge bar 328. The stack 324 includes a converter 330, abooster 332, and a horn generally designated 334 having a tool 338 witha forming cavity 340. The anvil 310 includes an upwardly directedcontact surface 344. Where necessary, a thin gasket or layer of othermaterial, such as a polyurethane elastomer (not shown) may be providedon the anvils if contact between opposed surfaces would be damaging tothe tool. In addition, the anvils thereunder may be made from atetrofluoroethylene (TFE) material so that they would not be damaged bycontact with the ultrasonic tool.

[0116] As will be understood by reference to FIGS. 7 and 8, the objectof this apparatus is to obtain the benefit of forming a highly contouredproduct without requiring a pair of ultrasonically energized cavities.As one way of achieving increased mechanical simplicity, the apparatusof FIGS. 7 and 8 does not require the stack and the anvils to have theirmovement sequences synchronized by precise timing arrangements or servomechanisms.

[0117] The conveyor belt 304 is advanced in steps by an intermittentdrive (not shown in detail) and as each individual blank or piece 320 a,320 b etc. of feedstock is taken from the feed source and placed ontothe anvil 310, the belt advances the cavity through one or more idlerstages and then stops the belt in a position of registration beneath theultrasonic stack 324. During the momentary period of registration whenthe anvil 310 is stopped beneath the stack 324, the drive for thereciprocable plunge bar 328 causes the bar to move downwardly, carryingthe bracket-mounted stack 324 with it and engaging the blank or piece offeedstock 320 received on the anvil with the opposed forming surfaces340 in the tool 338 and on the surface 344 of the anvil 310. The anvilmay have a contoured recess and a retaining mechanism, if desired, toprevent the piece from moving during indexing of the belt. In FIG. 7,the anvils are shown widely spaced apart for purposes of illustration.In practice, their position would depend on process parameters.Customarily, in this apparatus, since individual blanks of feedstock arepre-cut, cutting edges need not be provided on the tool.

[0118] However, the forming, which is done through the application ofultrasonic energy, is carried out in a very short time, such as fromabout 60 to 150 milliseconds (m sec), with the dwell time depending onthe type, consistency and conditioning of the material, etc. Theultrasonic action facilitates shaping by suitably plasticizing theproduct and by preventing the product from sticking to the vibratorycavity. The ultrasonic energy also vibrates the cavity sufficiently tosecure product release. Accordingly, simply inverting the anvil normallypermits the product to drop onto the other belt 316 for one or moresubsequent or downstream operations. If the anvil contains a cavity,dislodging the product can be achieved by tapping the anvil, byknockouts, or otherwise.

[0119] Referring now to FIGS. 10A and 10C, there is illustrated arelatively simple way in which the invention can be practiced. As shownin FIG. 10A, an apparatus generally designated 500 is shown forproducing three rows of individual products generally designated 502,each having a precisely cut silhouette from three continuous stripsgenerally designated 504 a, 504 b, 504 c of confectionery material.

[0120] In the illustrated embodiment, a full width supply conveyorgenerally designated 506 is shown to include a continuous belt 508, andone or more drive and/or tensioning pulleys 510. The conveyor 506 has anupper run 512 and a lower run 514. A product outfeed conveyor generallydesignated 516 is shown to be oppositely arranged and include acontinuous belt 518 trained over a drive and tensioning pulley 520 andserving to divide the continuous belt 518 into upper and lower runs 522,524. The individual pieces 502 of confectionery are supported on theupper run 522 of the conveyor 518 where they are taken to a site (notshown) for further processing or packaging.

[0121] According to the invention, an array of individual forming toolseach generally designated 526 is provided. Each tool makes precise cutsat selected points in each strip 504 a, 504 b, etc. of confectionerymaterial. As shown in FIG. 10C, each forming tool 526 includes a bodyportion 528, a continuous sidewall 530 of thin cross-section terminatingin a continuous sharp lower edge 532. The body and the sidewalls 528,530 of the tool 526 are energized ultrasonically in a manner similar tothat described in connection with the other embodiments. As thesidewalls 530 and cutting edges 532 of each tool 526 descend, thecutting edges 532 engage the associated strip 504 of confectionerymaterial, cutting individual articles 502 each having a characteristicsilhouette from the remainder of the stock 504. This operation leaves acontinuous remainder or web 534 of confectionery material which is ableto be recycled or reprocessed. In this embodiment, the lower edges 532of the sidewalls 530 move downwardly in operation until they contact theupper surface of the upper run 508 of the 512 of the conveyor belt.Thereupon, by the use of vacuum or otherwise, such as by the type ofamplitude profiling referred to elsewhere herein, each piece 502 havingthe precisely cut silhouette is in turn picked up and transferred to theoutbound conveyor 516.

[0122] The ultrasonic actuation of the walls and their lower edgesserves to form a precise cut, and the schematically illustrated toolingis capable of making a product having a silhouette of very fine detail.Unlike the apparatus used in other illustrated embodiments, no attemptis made to reform or reshape the product, nor to emboss, deboss orotherwise add texture, relief or surface finish to the top or sidewallsurfaces of the product. The embodiment just described illustrates theoperational principle of utilizing the vibratory edges for purposes ofproduct cutting only. As pointed out in connection with the otherexamples, an important advantage is that the vibratory action totallyeliminates build up of residues on the cutting edges and enhances thecutting process where inclusions are encountered.

[0123] A movement mechanism (not shown in detail) similar to thatillustrated in connection with FIGS. 1-2 is utilized to control theplunging or descent movement of the cutting apparatus, its synchronousmovement with the conveyor belt and its lifting and transferring of thefreshly cut part to an adjacent conveyor or other suitable location. Itis possible to incorporate vacuum and/or air pressure as an aid topicking up and releasing the individual products being formed. Othersuitable mechanisms known to those skilled in the art may be used forthis purpose. Such mechanisms do not form a novel part of the presentinvention, and accordingly, not being necessary for an understanding ofthe instant inventive principles, a detailed description of them isomitted.

[0124] Referring now to FIG. 10B, an apparatus generally designated 550is shown to be provided for producing groups 552 of products from eachof a plurality of forming tools 554 arranged for movement of the typedescribed and illustrated in FIGS. 1, 1A and 2 and shown by thedirectional arrows in the drawings. Here, the supply conveyor 556includes a continuous belt 558, trained over one or more drive and/ortensioning pulleys 560. The feed or supply conveyor 556 also includes anupper run 562 and a lower run 564. An adjacently disposed productoutfeed conveyor generally designated 566 is also shown to includeprovide continuous withdrawal of form products. The conveyor 566includes a drive continuous operation over drive and tensioning pulley570 dividing the belt 568 into upper and lower runs 572, 574, as well asother runs shown only partially. Individual groups 552 of confectioneryproducts, each including plural products 551, 551 a, 551 b, etc. aresupported on the upper run 572 of the conveyor.

[0125] Here, as in FIG. 10A, there are a plurality of forming tools 576,each having a body portion 578 provided with multiple cavities definedin part by multiple continuous thin sidewalls 580 and continuous sharplower edges 582. Their manner of being energized and their motionsequence is the same as that illustrated in FIGS. 1, 1A and 2 and thesame as that described in connection with FIG. 10A. The only differenceis that the residual webs of material 554 contain plural groups ofopenings 585 rather than plural individual openings.

[0126] Of course, in keeping with the invention, it is possible to usemultiple cavity apparatus in multiple tool arrays in order to makeproducts that are cut and formed as well as merely cut. In suchinstance, the operational principles remain the same and only the typeor style of cavity would be different.

[0127]FIG. 16 is a block diagram showing the form of operation or methodcarried out with the apparatus of FIGS. 1-2, FIG. 10A and/or FIG. 10AA.As is apparent from FIG. 16, a strip of confectionery material iscontinuously advanced, as by a conveyor. At a selected point, the stripis engaged by the tool which moves downwardly into engagement with thestrip and which is moving at a synchronous rate relative to the strip.

[0128] Ultrasonic energy applied during contact between the tool and thestrip assist the tool in cutting and forming a piece of product. Afterthis strip is completed, the tool is accelerated forward so as toseparate the just-formed product from the still advancing, leading edgeof the strip. Thereupon, the tool is lifted out of contact with thestrip. The tool is then returned to its initial position for repetitionof the cycle, while the just-formed product is transferred to the outputconveyor.

[0129] Referring now to FIG. 13, there is shown an ultrasonic toolgenerally designated 700 which includes an attaching fastener 702 forattachment to a booster or the like. The body portion 704 of the tool700 includes a cavity generally designated 705 defined by inner endwalls 706, inner side walls 708, and a plurality of divider walls 710.According here to the inventive concept, the divider walls 710 terminatein lower edges 712 which are somewhat raised in respect to the extent ofthe bottom surfaces 714 of the side and end walls 706, 708. The inner ortop wall 716 of the cavity 705 may or may not be embossed or otherwisetextured, depending on the form of final products sought to be madeusing the tool 700.

[0130] As is shown in FIG. 13, the main purpose of forming the tool 700in the manner illustrated is to produce a segmented bar 718 havingportions generally designated 720 of reduced cross-section or weaknesslying between the individual segments 722 making up the bar 718 as awhole.

[0131] Referring now to FIG. 14, an illustration is presented of a formof confectionery product such as a candy piece or bar generallydesignated 830 having a body 832 defined in part by plain or unadornedside walls 834 and shown to include a contoured or relieved design 836on the upper surface 838 of the bar or piece 830. Such a generally flatbut relieved upper surface is readily formed using an ultrasonicallyactivated tool having a cavity with the reverse image of the productshown. In the type of product shown, it is assumed that the side walls834 are formed by use of ultrasonic cutting edges on the cutting andforming tool (not shown).

[0132] Referring now to FIG. 15, a novelty-type candy or otherconfectionery product generally designated 860 is shown. Here, the body862 of the product is shown to include side walls 864 and end walls 866of different heights, and to include an upper surface 868 that isheavily contoured. In the illustrated case, the form of a rabbit 870 isshown to have relatively deep relief. Such a product may be formed usinga deeply contoured cavity but the potential for making deep reliefproducts, with or without flat side walls made by ultrasonic cutting isillustrated in FIG. 15.

[0133] Referring now to FIG. 9 and FIGS. 11A-11C, another importantaspect of the present invention is shown. This aspect results from therealization that it is not necessary to energize the forming cavitycontinuously with the maximum ultrasonic amplitude attainable. Instead,the amplitude of the ultrasonic motion of the cavity surfaces, which isindicative of the energy being transferred, is varied periodically. Inparticular, it is not necessary to maintain the maximum amplitude whenthe forming horn is not in contact with the product. According to theinvention, therefore, the horn is preferably operated at two or moredifferent amplitude levels during processing, depending on the makeup ofthe product and other forming parameters.

[0134] Thus, and referring for example to a sequence of the typedescribed in connection with FIGS. 1 and 2, the energy fed from thepower supply to the converter is controlled in such a manner that duringindexing of the ultrasonic stack to a position in alignment with andabove the stick of material, a lower amplitude is used, perhaps 20 to30% of the maximum available amplitude. Just before the tool is movedadjacent and into contact with the stick of confectionery product, thepower supply output rapidly ramps up to achieve an amplitude which is ahigh percentage of the maximum amplitude theoretically available, and isequal to what could be termed the normal design amplitude of the tool.Energy is then supplied at this amplitude until the cutting and formingoperation is complete, with the power supply then returning to its lowamplitude mode until the remainder of the cycle is repeated.

[0135] Referring now to FIG. 11A, there is shown in graphic form anillustration of the concepts referred to generally above. FIG. 11A showsgraphically that there is a maximum design amplitude level A_(maxD), amaximum normal or duty cycle amplitude A_(maxN) which may be 70% to 85%of A_(maxD), and another amplitude A_(MIN) which is the minimumamplitude at which the forming tool will operate. This level maytypically be some 30% of A_(maXD). Thus, FIG. 11A illustrates attainingtwo operative levels A_(MIN) and A_(maxN) between zero level and amaximum design amplitude, i.e. the maximum amplitude A_(maxD) at which atool could be made to operate.

[0136] The actual amplitude level achieved from time-to-time is shown bya line generally designated 400 and shown to have an initial, idling oroff-duty portion 402, an inclined portion 404 wherein the amplituderamps up until it reaches and levels off at the A_(maxN) 406. Here, itremains for a significant time before ramping down as at 408 to theidling level 402 which is equal to its energized but low output leveljust discussed.

[0137] Referring again to FIG. 11A and the legends beneath the curveillustrating the amplitudes, it will be noted that one complete cycle isdesignated T_(C). This cycle time, which is repeated periodically duringoperation of the machine, comprises a number of components which arelisted at the bottom of FIG. 11A. From left to right, these are theT_(RU) or “ramp up” time, a dwell time T_(D) wherein the tool isactually in contact with the confectionery product and fully energized,the time T_(RD) is a transient, “ramp down” period during which theamplitude decreases from A_(maxN) to A_(min). Thereafter, T_(A) or the“air” time is the time at which the forming tool is in the air, i.e.disengaged from the product.

[0138] The air time is used for the return and reset portion of thecycle. Accordingly, and referring for example to a cycle of the type ofillustrated in FIGS. 1, 1A and 2, the acoustic tool 70 would becontinually energized, but maintained at the relatively low levelamplitude A_(min) until just prior to entering the work, i.e. beingplunged into the strip of confectionery material. During the time justprior to this movement, the energy level would ramp up so that, uponfirst contact, the amplitude would be at A_(maxN). This amplitude isthen maintained until such time as the tool is withdrawn. Thereafter theamplitude ramps down to the idling or low amplitude level A_(min) untilthe tool is repositioned and the cycle is to be repeated.

[0139]FIG. 11B shows a concept similar to that of FIG. 11A except thatthe total cycle time T_(C) is divided differently. Here, there are twopeaks of different duration, each accompanied by a ramp up and ramp downperiod. The ramp up and ramp down times are not illustrated in the lowerportion of the legend, wherein the duty or dwell cycle is subdividedinto different components. Thus, a time period T_(F) is shown whereinmaximum amplitude is achieved during the forming portion of the cycle,which includes the initial entry into the confectionery strip andextends through the time at which the entire inner cavity surfaces havecontacted appropriate portions of the strip and completed the formationof the product.

[0140] Thereafter, there may be a period T_(I) or an idling time whereinthe acoustic tool has completed forming the product but is still incontact with it. After time, T_(I) has elapsed and it is desired toachieve or insure separation of the formed product from the leading edgeor surrounding portions of the strip, the tool is again energized at ahigher level for a period of time illustrated as T_(R) or, release time.When the maximum amplitude is again applied to the tool, the formedpiece is released from the horn cavity. Thereafter, a period T_(A) or“air time” of the tool occurs that is the same as that discussed inconnection with FIG. 11A.

[0141] Referring to FIG. 11C, a similar concept is illustrated, exceptthat some of the ramp up and ramp down times are shown as exponential.This is because, for practical reasons, the ramp up rates may actuallytaper off, or it may be desired to modulate the rate of ramping up ordown. In the illustrated case, one ramp down portion of the cycle is apartial or incomplete ramp down, i.e., the amplitude does not go as lowas the initial or air time minimum amplitude.

[0142] Here, in FIG. 11C, the expressions beneath the curves have thesame meaning as their counterparts above, namely, T_(RU) and T_(RD) areramp up and ramp down times respectively and, T_(D) is the dwell time orforming and or cutting time while T_(R) is the release time.

[0143] Referring now to FIG. 11D, a similar concept is shown whereinthree separate levels of amplitude are shown, as well as a zero orinactive state. This profile might be used in a “pick and place”operation. In the profile illustrated, the portion of the curve 450 isan “air” time which occupies a given duration prior to beginning of theforming cycle. This is followed by a ramp up time 452 and a dwell time454 wherein formation of the product is taking place. The ramp down time456 follows forming of the product and terminates at a zero levelwhereat the tool is de-energized. Thereafter, a ramp up time occurs justafter which a maximum or release amplitude 460 is created for a briefduration, following which a ramp down time 462 elapses as the tool isthereafter returned to an active but idle or air time amplitude as shownat 464.

[0144]FIG. 11D shows that various levels may be achieved for particulardesired purposes and that it is not necessary that the maximum orminimum useful amplitudes be the same as their counterparts in the otherillustrations. In other words, the energy level for formation and thatfor release may be different; the idle or air time amplitude may be thesame but may also be zero (no ultrasonic energy) between portions of thecycle.

[0145] One application is a “pick and place” sequence wherein it isdesired to have no post-formation energy imparted during a transfertime, after which the cavity is energized strongly to secure productrelease.

[0146] Depending on the exact nature of the product and the application,variations in dwell times and amplitude values may be desired by thoseskilled in the art. This process may be referred to collectively as“amplitude profiling.”

[0147] This ability to achieve different levels of amplitude at the hornface cavity is easily accomplished by the combination of a dedicatedcontroller and a standard power supply.

[0148] The amplitudes of vibration may vary depending upon the power andtool design. However, with frequencies of 20 KHZ being used to moldlarger pieces and another frequency, such as 40 KHZ, being used to makesmaller pieces, the amplitudes that have been found useful have rangedfrom 5 microns at an “off duty” or idle level such as that illustratedin FIGS. 11A-11D, and up to 15-20 microns at the 80% level shown at 406in FIG. 11A. Representative amplitudes that are believed useful on anoverall basis vary from 5 to 100 microns as a probable maximum with fromabout 5 up to about 20 to 35 microns being the presently preferredrange.

[0149] In this connection, reference is made to FIG. 9. Thisillustration is very schematic, but it shows that, when power is appliedto the ultrasonic stack, standing wave generally designated 600 in FIG.9 is developed in the forming tool or horn. Such a wave 600 has a nodepoint 602 and a pair of anti-nodes or high amplitude portions 604. Asthe amplitude of such a wave increases, at the same frequency, (as shownby the dotted line wave form 606), the applied power or energyincreases.

[0150] When a forming tool 608 is designed so that a standing wave ispresent in the tool, as illustrated, the node portion 610 of the formingtool will be substantially stationary, regardless of the amplitude ofthe other portions of the wave. As the amplitude of the standing waveincreases, the displacement of the anti-node portion of the wave alsochanges, causing the cavity face and edges of the tool 612, 614, tomove, within limits, to different excursion levels, i.e., higheramplitude vibrations. Once a certain amplitude has been reached,additional energy input may raise the force of the vibrations withoutincreasing their amplitude. Energy application is controlled by thepower supply as necessary, usually resulting in an amplitude that rangeswithin those limits described in connection with FIGS. 11A-11D.

[0151] Referring now to the use of the inventive methods and apparatusto make puffed cereal products, FIGS. 17-21 illustrate such materialsand methods of manufacture. Basically, the process illustrated in thesefigures is similar to that carried out by the apparatus of FIGS. 1-2, orthat of FIGS. 10A-10AA. As shown in FIG. 17, for example, an individualconfectionery product in the form of a contoured FIG. 1016 is shaped ina cavity generally designated 974 and shown to be defined by contouredinner surfaces 972 on a portion of an ultrasonic horn generallydesignated 970.

[0152] It is understood that the horn 970 with the cavity 974 ispositioned in abutting relation to a powered booster (not shown). Asillustrated by the double headed sets of arrows in FIG. 21, the entireultrasonic stack assembly, including the horn/booster and converter ismovable both in a plunge-and-retract or vertical mode, and in ahorizontal mode. In this instance, the assembly including the horn 970and the cutting and/or forming surfaces 972 are moved by a mechanism(not shown) which is the same as or similar to that shown in FIGS. 1-2or 10A-10AA, for example. The sequence of movement is also the same.Thus, the apparatus includes an infeed or supply conveyor generallydesignated 926 having an infeed belt generally designated 984. The beltis trained over various rollers, including a guide roller, 990 and ismade to form an upper run 996 and a lower run (not shown). A backingplate 995 supports the portion of the upper run 996 of the belt 984 nearthe roller 990. A continuous supply or strip of confectionery feedstock998, similar to its counterpart 98 shown in FIG. 1A (except that thefeedstack 998 comprises puffed cereal grains), is fed forward as thebelt 984 moves.

[0153] An outfeed conveyor generally designated 928 is shown to have atleast one guide roller 1010 serving to guide a drive belt generallydesignated 1011, the upper run 1012 of which supports newly formedproducts 1016 and removes them from the formation area in which the toolwith the horn 970 moves in the sequence just referred to. As in itscounterparts shown in FIG. 1, the linear speed of the outfeed conveyor928 is higher than that of the infeed conveyor 926. This enables thejust-formed products 1016 to be spaced apart from one another and to beaccelerated away from the forming area just after the products are made.

[0154] The movement sequence of the cutting and forming tool is similarto that described in connection with FIGS. 1-2 in that the horn followsthe advancing strip of material at the rate of advance, plunges downinto the material to cut and form a piece, and then accelerates toseparate the just-formed piece from the leading edge of the continuouslyadvancing stick. Thereafter, the stack lifts and returns to its originalposition before beginning another cutting and forming sequence.Furthermore, as shown in FIGS. 12A and 12B, the feedstock 998 may be andpreferably is of generally higher and narrower cross section than thefinished product generally designated 1016. Likewise, the cavity 974 issomewhat longer than the initial length of the end portion 1117 thatwill be severed from the feedstock strip 998. This is illustrated bycomparing FIGS. 17 and 21 with FIGS. 18-19A.

[0155] Thus, in FIG. 18, there is shown a strip 998 a of confectioneryproduct having a height “H” and a width “W”, and a segment length “L”.Referring to FIG. 17, the height “H” of the product 1016 illustrated islower, the width “W” greater than that of the forming stock 998 a, andthe length “L” of the product (FIG. 21) longer than the end portion1117. The volume of the end portion 1117 is such that it exactly matchesthe volume of the tool cavity 974, and hence the cavity will be filledby the just-cut end 1117.

[0156] The material, through the application of ultrasonic energy,becomes plasticized sufficiently to enable it to be reformed withoutchanging the essential texture of the puffed cereal product, ordestroying the adhesion between the individual grains of productprovided by the matrix.

[0157] By comparing FIG. 21 to FIGS. 12A and 12B, which also shows aforming process, the similarities in the processes can be seen. Thus, inFIGS. 12A and 12B, the trailing edge of the tool cuts a leading edge1113 of the strip of product. Volume matching is achieved because thefinished product is of decreased length and height, and increased width,relative to the generally rectangular end section of the stick of puffedcereal stock.

[0158] Referring again to FIG. 18, an illustrated segment 1117 of thepuffed cereal generally designated 998 a is illustrated. As shown, theindividual grains of the puffed cereal, which by nature have relativelylow compressive strength, are bonded together by surface contact. Thebinding for such product may be achieved by the action of gluten, starchor other component of the cereals having similar inherent adhesiveproperties, especially as these are developed during the heating andprocessing of the cereal. In this case, no adhesives are intentionallyadded. If surface adhesives are utilized, they usually constitute a verythin coating for the grains of cereal.

[0159] Referring to such adhesives, a coating of a suitable bindermaterial is sometimes added to the prepuffed cereal grains prior tocompression. Such a coating may, for example, comprise a cereal flour, asugar or an edible gum. Suitable cereal flours include rice flour, wheatflour and corn flour. Suitable sugars include dextrans, maltodextrins,syrups of glucose, fructose, maltose, sucrose or mixtures thereof, andcaramels. Suitable edible gums include xantham gum, guar gum,carrageenan, locust beam gum and mixtures thereof. Other adhesivesinclude zein and modified vegetable fats.

[0160] Preferably, most or all such binders comprise aqueous liquids.One preferable coating comprises at least 80% w/w of water, mostpreferably at least 95% of water. The aqueous liquid coating may containdissolved vitamins, colorants or flavoring agents. Preferably, theaqueous liquid is sprayed onto the puffed cereal grains shortly beforethe compression step, preferably no more than 60 seconds before thecompression step, and most preferably no more than 20 seconds before thecompression step. It is thought that water assists the binding of theprepuffed cereal grains by softening and partially dissolving componentsat the surface of the grains, including local activation of the starch.In addition, water is a good susceptor for ultrasound and will tend tolocalize ultrasonic heating at the surfaces of the puffed grains, wherebonding takes place. Because water absorption can cause a loss ofcrispness or chewability in puffed cereals—thus compromising favorableeating characteristics—steps should be taken to insure that this doesnot occur. Preferably, the grains of cereal are coated with a moisturebarrier to prevent water absorption if either the matrix or a flavoringcoating is formulated so as to allow water to migrate from the matrix orcoating into the grains. The permissible amount of water used can bedetermined by those skilled in the art when addressing the makeup of theparticular binder, adhesive, flavoring coating, etc.

[0161] In some cases, the binder coating is applied to the prepuffedcereal grains in an amount of from 0.1 to 100% by weight, morepreferably 5 to 50% by weight, and most preferably 10 to 30% by weightbased on the dry weight of the prepuffed cereal grains. The bindercoating may also be applied to the edible inclusions, where these areadded to the cereal grains. Preferably, the binder does not make up morethan 10% by volume, more preferably not more than 2% by volume, and mostpreferably not more than 1% by volume of the puffed cereal.

[0162] Referring to caramels, and some syrups or sugars, these may formthe illustrated matrix rather than being merely a binder. Of course, itis understood that these binding steps have taken place in order to formthe sticks, ropes or slabs of stock before they are post-formed by theprocesses described herein and illustrated in FIGS. 1-2, 10A-10AA, etc.

[0163]FIG. 19 shows the end portion of a strip generally designated 998b wherein inclusions 999, 997 are shown among an array of puffed grains1001, all held together by a plasticizable matrix 1003. A stick of suchmaterial is plasticized, cut or formed just as is its counterpart inFIG. 18, using the ultrasonically energized tool of FIG. 17 or 21, forexample. FIG. 19 shows the end portion of a strip generally designated998 c which is the same as that in FIG. 19 in all respects except thatthe inclusions 1005 are shown as being nuts or other relatively hardinclusions.

[0164] The end portion of an extruded rope generally designated 998 d isshown in FIG. 20. The rope differs from the slabs or sticks of FIGS.18-19A. In FIG. 20, no inclusions are shown, and the rope 998 d is heldtogether by surface binding. There is no plasticizable matrix ofmaterial present between individual grains of puffed cereal 1001. Thepuffed cereal material is formed in a rope configuration such as thatshown in FIG. 20 as it leaves the extruder. If the rope is engaged bythree dimensional tools as shown in FIG. 17, while it is still pliable,surface texture or a particular shape may be imparted to the product. Ifit is not processed within a second or two, usually a fraction of asecond, it will set into a characteristic shape in cross-section andcannot be further shaped.

[0165] Depending on the nature and extent of binder, the ultrasonicenergy can be used in the cutting and/or forming process to achievetypes of product formation that has heretofore been deemed impossible orimpractical. The use of ultrasonic energy is a non-destructive manner ofeffectively plasticizing the adhesive matrix components of a strip toenable the puffed grains to be rearranged without being destroyed, andthis ability enables shapes of altered depth or width relative to aninitially formed product stick to be made. In particular, the method andapparatus enable products of widely varying contours and surfacetextures to be made.

[0166] With the recent popularity of puffed rice and other puffed cerealproducts, the ability to create shapes that are attractive, particularlyto younger consumers, is very important, and this is a significantfeature of the present invention.

[0167] Referring now to other aspects of the invention, forconfectionery use, it has been found preferable to form the tooling fromtitanium alloys. The-mechanical properties of these alloys, and theircompatibility with confectionery products combine with their desirableacoustic properties to render them highly suitable for use with theapparatus of the invention. Regarding the form of confectionery productswith which the process and apparatus are effective, candy bars, “frozen”confectionery products, and other confectionery products such as fudge,chocolate, toffee, caramel, nougats, etc. can be cut and formed usingthe apparatus of the invention. Some such products can be used asformed, and others can be enrobed with chocolate. Various highproduction, continuous type methods having been described in detail, itwill be apparent to those skilled in the art that if it is desired forany reason to conduct manufacturing on a reduced scale, this is alsopossible.

[0168] While the applicant does not wish to be bound by any particularprinciple or theory of operation, it is believed that the combination ofmechanical forces and ultrasonic energy combine to plasticize aconfectionery product in the form of a strip, rope or slab sufficientlyto reform it but without melting the strip. The plasticity enables theproduct to be shaped under comparatively moderate forces and to achievevirtually 100% cavity filling. The amplitude of the vibration of themolding surfaces is such that a fine surface finish can be imparted tothe product and yet virtually 100% cavity release can be achieved.Normally, there is no detectable product build up on the interior of theforming cavity even after a substantial period of time.

[0169] The temperature of the extrusion or slab for most candy productsis commonly maintained just above room temperature, usually in the 18 to35° C. range. Other products are processed at different temperatures.The vibratory motion imparted to the cutting edges of the tool of theforming tool enable relatively hard inclusions, such as nuts or thelike, to be cut without incident.

[0170] The comparatively simple positioning of the ultrasonic stack formovement and the availability of servo motors or other controlmechanisms renders the process equipment capable of inclusion intoexisting production lines without disruption or addition of significantcost. Thus, existing extruders, packagers, and the like may be utilizedwithout change or modification.

[0171] In the embodiment of FIGS. 1, 1A and 2, an output conveyoroperating at a higher speed than the input conveyor is illustrated, butas long as the individual products made are spaced from the leading edgeof the slab, such conveyor speed is not absolutely necessary.

[0172] The apparatus and method described have been proven capable ofrendering a strip or slab of confectionery material usable to create aparticular taste, consistency and eating characteristics in a givenproduct as the feedstock for producing true analog products, i.e. thosehaving those same characteristics in a product of an entirely differentshape. Complex shapes and shapes with rounded bottoms, textured surfacesand the other characteristics described herein can readily be made.

[0173] It will thus be seen that the present invention provides severalmethods and apparatus for forming confectionery products andrepresentative embodiments having been described by way of example, itis anticipated that variations to the described forms of apparatus andmethod will occur to those skilled in the art and variations and thatchanges may be made in such methods and forms of apparatus withoutdeparting from the spirit of the invention or scope of the appendedclaims.

I claim:
 1. A method of forming individual pieces of confectioneryproduct having a characteristic shape and surface finish, said methodincluding the steps of creating an ultrasonic product forming toolhaving node and antinode portions, forming a cavity in the vicinity ofsaid anti-node portion, said cavity having a desired interior shape,surface finish and being defined in part by margins forming at least onecutting edge portion, positioning said forming tool adjacent acontinuously advancing strip of confectionery stock moving along a givenpath, energizing said forming tool so as to cause said cavity surfaceand said cutting edge to vibrate through a given amplitude at anultrasonic frequency, and periodically moving said forming tool intocontact with and through an end portion of said advancing strip ofconfectionery stock so as to simultaneously cut said stock intoindividual pieces, and form each individual piece into a finishedconfectionery product having a shape and surface finish corresponding tothat of said forming tool, and separating each of said pieces thusformed from said strip of confectionery stock.
 2. A method as defined inclaim 1 wherein said tool is ultrasonically vibrated at a frequency ofat least 10 kHz.
 3. A method as defined in claim 2 wherein the frequencyof vibration is from about 20 kHz to about 40 kHz.
 4. A method asdefined in claim 1 wherein said tool is in contact with said supply ofconfectionery feedstock for a period of from about 30 to about 200milliseconds.
 5. A method as defined in claim 4 wherein said tool is incontact with its supply of confectionery feedstock for a period of fromabout 80 to about 180 milliseconds.
 6. A method as defined in claim 1wherein the amplitude of vibration of said tool surface in contact withsaid strip is from about 10 to about 100 microns.
 7. A method as definedin claim 6 wherein the amplitude of vibration of said surface is fromabout 10 to about 50 microns.
 8. A method as defined in claim 1 whereinthe frequency, contact time and amplitude of vibration of said tool aresufficient to plasticize said stock of confectionery material in contactwith said tool without substantial heat generation, whereby the taste,consistency and eating characteristics of the ingredients of saidconfectionery stock are not significantly altered.
 9. A method asdefined in claim 1 which further includes the steps of depositing aconfectionery coating onto said individual confectionery products cutand formed as defined in claim
 1. 10. A method as defined in claim 1wherein said stock of confectionery material comprises plural individualgrains of a puffed cereal, the outer surfaces of said grains being insurface contact with the outer surfaces of adjacent grains.
 11. A methodas defined in claim 1 wherein said confectionery material comprises arice cake material.
 12. A method as defined in claim 1 wherein saidconfectionery material is a material containing puffed rice grains, saidmaterial further including a substantially continuous, edible, heatplasticizable matrix securing said grains of puffed rice to one another.13. A flashless molding method for forming a plurality of substantiallyidentical, individual finished confectionery products each having agiven finished volume from a continuous supply of a confectioneryproduct feedstock having a given taste, consistency and eatingcharacteristics, said method comprising the steps of determining thecross-sectional area of said feedstock, advancing said continuous supplyof confectionery product feedstock, and, utilizing a cutting and formingtool having a cutting edge portion and a cavity of a given volume andhaving interior surfaces of a desired shape and texture, imparting anultrasonic vibratory motion to said cutting and forming tool,periodically forming sections of said feedstock to the shape and textureof said cavity inner surface and cutting said sections to a length suchthat, given said cross-sectional area of said feedstock, the volume ofeach of said cut sections will equal said given volume of said cavity,and whereby said individual finished confectionery products will besubstantially flash-free.
 14. A method as defined in claim 13 whereinsaid feedstock has a height greater than that of said cavity and whereineach section has a width and length less than that of said cavity.
 15. Amethod as defined in claim 13, wherein said tool is ultrasonicallyvibrated at a frequency of at least 10 kHz.
 16. A method as defined inclaim 13, wherein the frequency of vibration is from about 20 kHz toabout 40 kHz.
 17. A method as defined in claim 13, wherein said tool isin contact with said supply of confectionery feedstock for a period offrom about 30 to about 200 milliseconds.
 18. A method as defined inclaim 13, wherein the frequency, contact time and amplitude of vibrationof said tool are sufficient to plasticize said stock of confectionerymaterial in contact with said tool without substantial heat generation,whereby the taste, consistency and eating characteristics of theingredients of said confectionery stock are not significantly altered.19. A method as defined in claim 13, wherein said continuous supply ofconfectionery product feedstock comprises a supply of a puffed cerealmaterial wherein the individual grains of puffed cereal are bonded toone another by a surface coating of a material having an adhesivecharacter.
 20. A method as defined in claim 19, wherein said individualgrains of puffed cereal are embedded in a substantially continuousmatrix of an edible, heat plasticizable material.
 21. A method asdefined in claim 20, wherein said edible, heat-plasticizable materialincludes caramel.
 22. A method as defined in claim 19, wherein saidcereal comprises rice.
 23. A method of forming a plurality of individualconfectionery products each having a desired three dimensional shape anddesired surface finish, said method including providing a pair ofopposed ultrasonic product forming tools each having a product formingcavity in its end face, each of said cavities having a desired interiorshape and surface finish and each being defined in part by marginsforming at least one cutting edge portion, positioning said pair offorming tools with said cavities in opposed facing relation and spacedapart by a predetermined distance, continually advancing a continuoussupply of confectionery product from a supply source and over a supportsurface along a given feed path at a predetermined continuous rate,periodically lengthening said feed path by moving said support surfacein a direction opposite the direction of said advancing feedstock at arate equal to said feedstock advancing rate, thereby rendering saidfeedstock strip immobile for a given duration, and during said givenduration, contacting a portion of said feedstock with said cutting edgesand said cavity interiors to cut and form a finished piece, subsequentlywithdrawing said tools from each other and moving said support surfacein the direction of said feedstock advance so as to shorten said feedpath by an amount equal to the amount said feed path was previouslylengthened, and continually repeating said feeding, cutting and formingcycles to create a succession of individual confectionery products. 24.A method as defined in claim 23, wherein said movable support comprisesa roller having a peripheral, product-engaging surface, said and whereinlengthening said feed path comprises moving said roller vertically bymeans of a linear actuator.
 25. A method as defined in claim 23, whereinsaid feed path includes a portion downstream of said support surfacewherein said continuous supply of said confectionery product movesvertically under the influence of gravity.
 26. A method of formingindividual pieces of confectionery material from a continually advancingcontinuous rope of confectionery material, said method includingperiodically shortening and lengthening the effective feed path of thearticle to periodically start and stop the motion of the strip leadingedge and an adjacent portion of said rope, moving at least one anultrasonically energized forming tool into contact with said adjacentportion of said rope during the time said leading edge and adjacentportion are stationary and periodically repeating this cycle to formsaid individual pieces of confectionery material.
 27. A method asdefined in claim 26, wherein said at least one ultrasonically energizedforming tool comprises a pair of opposed forming tools.
 28. A method ofmaking formed confectionery products including pre-cutting confectionerystock into individual pieces of a desired shape and length, periodicallypositioning said pieces thus formed onto an anvil unit having a desiredshape and surface finish, successively contacting said individual pieceson said anvil with a forming tool having a cutting edge and a formingcavity of a predetermined shape and surface texture, and energy saidforming tool by ultrasonic vibration during the portion of said formingcycle in which pieces are supported on said anvil and in contact withsaid tool.
 29. A method as defined in claim 28, wherein said ultrasonicvibration occurs at a frequency of from about 10 kHz to about 40 kHz.30. A method as defined in claim 28, wherein said portion of saidforming tool energized by said ultrasonic vibration moves through anamplitude of from about 10 to about 50 microns.
 31. A method as definedin claim 28, wherein a frequency, contact time and amplitude ofvibration of said tool are sufficient to plasticize said stock ofconfectionery material in contact with said tool without substantialheat generation, whereby the taste and consistency and eatingcharacteristics of the ingredients of said confectionery stock are notsignificantly altered.
 32. A method as defined in claim 28, wherein saidindividual pieces of confectionery stock comprise pieces of a puffedrice cake material.
 33. An apparatus for continuous manufacture ofconfectionery products, said apparatus including a frame, an inputconveyor secured to said frame and including upper and lower runportions and a drive mechanism adapted to operate said conveyor at afirst given speed; an output conveyor secured to said frame and havingan upper run, a lower run and a drive mechanism adapted to operate saidoutput conveyor at a second higher speed, said output conveyor beingpositioned adjacent and downstream of said input conveyor, said outputconveyor being adapted to receive products formed on a downstream endportion of the upper run of said input conveyor, an ultrasonic stackincluding an energy converter for changing electrical energy intoultrasonic vibration, a booster for increasing the amplitude of saidvibration and an ultrasonic horn having surfaces defining a cutting edgeand a forming cavity with a predetermined interior shape and surfacefinish, a carrier for said stack, said carrier being positioned by aportion of said frame, and at least one motor and control for movingsaid stack generally parallel to said downstream end portion of the saidupper run of said input conveyor, a mechanism for plunging said stackfrom a raised initial position to a lowered position adjacent said upperrun of said input conveyor, thus enabling said stack to be lowered intocontact with a portion of a continuous supply of confectionery materialpositioned on said upper conveyor run at said first rate so as to besynchronized with the movement rate of said upper run, said mechanismalso being capable of accelerating said stack away from the leading edgeof said continuous supply of confectionery material so as to space anindividual piece formed by said cavity from said leading edge and into aposition adjacent the upstream end said upper run of said outputconveyor, and said mechanism further being adapted to move said cavityout of engagement with of stack and to return said stack to said initialposition.
 34. An apparatus as defined in claim 33, wherein said inputconveyor further includes a support plate beneath its upper run adjacentsaid downstream end of said conveyor.
 35. An apparatus as defined inclaim 33, wherein said motor and control is in form of a programmableservomotor.
 36. An apparatus including a feeder for providing acontinuous rope of confectionery product of given a cross-section andadvancing said rope along a feed path, a positioner permitting said ropeto extend vertically under the influence of gravity while being advancedalong said feed path, a control for said positioner adapted to alter thelength of said feed path so as to lengthen and shorten said path fromtime-to-time, whereby said path may be lengthened at a rate equal tosaid feed rate to stop movement of said rope along said feed path, andshortened so as to accelerate said feed rate, said apparatus furtherincluding at least one ultrasonically energized stack comprised of aconverter, a booster and a confectionery product forming tool, a stackpositioner for moving said forming tool into engagement with at leastthe portion of the rope adjacent its leading edge when said leading edgeis stopped, and for releasing a formed product prior to shortening saidfeed path of said rope means to permit resumption of advancement by saidleading edge.
 37. A method of forming individual confectionery products,said method including providing an ultrasonically energizable cuttingand forming tool having a cavity of a predetermined shape, surfacetexture and a cutting edge portion, imparting an ultrasonic vibration tosaid cutting and forming tool at a given frequency and a firstamplitude, adding power to said tool so as to increase said amplitude toa second higher amplitude and moving said cutting and forming tool intocontact with a strip of confectionery material while said surfaces andedge portions are being energized at said higher amplitude, therebyforming an individual confectionery product, releasing said product fromsaid cavity, and decreasing said amplitude to said first amplitude untilsaid cavity and cutting edge are again positioned for engagement withsaid strip of confectionery material.